Electronic devices comprising two encapsulant films

ABSTRACT

An electronic device comprises a first encapsulating film in direct contact with a light-receiving and transmitting film and a second encapsulating film in direct contact with a back sheet. The first encapsulating film has a zero shear viscosity greater than that of the second encapsulating film. The back sheet of the electronic device contains fewer bumps than the back sheet of a comparable electronic device having a first encapsulating film with a zero shear viscosity less than or equal to that of the second encapsulating film.

FIELD OF THE INVENTION

This invention relates to encapsulation films and electrical devicescontaining encapsulation films. In one aspect the invention relates toencapsulation films which provide electrical insulation andenvironmental protection for active solar cells while in another aspect,the invention relates to an electric device having at least twoencapsulant layers having a difference in viscosity.

BACKGROUND OF THE INVENTION

Encapsulation films offer insulation and environmental protection forelectrical components used in electronic devices, such as solar cellsused in PV modules. Encapsulants can act as a skin for electronicdevices or completely enclose the device.

In the construction of a typical silicon-based photovoltaic (PV) module,there is a front glass layer followed by a front encapsulant, the solarcells, a back encapsulant and, finally, a back sheet. These layers arelaminated at elevated temperatures to create the solar module.

The polymer material currently used in the back sheet of a solar moduletends to shrink when exposed to the high temperatures necessary toproperly laminate the solar module layers. Shrinkage of the back sheetis transferred forward to the other layers of the solar module, causingthe individual PV cells within the solar module to be pulled closertogether and the ribbons connecting the individual cells to crimp, orbend back against the back sheet.

The back sheet is therefore displaced during lamination. Afterlamination, visible bumps are present in the back of the solar module,decreasing the module's overall aesthetic appeal. The solar module mayalso not work properly due to the PV cells' movement and ribbon-crimpingexperienced during lamination.

Of interest are encapsulant films which prevent the transfer of movementas a result of shrinking from the back sheet of a solar module to therest of the unit.

SUMMARY OF THE INVENTION

In one embodiment the invention is an electronic device comprising afirst encapsulating film in direct contact with a light-receiving andtransmitting film and a second encapsulating film in direct contact witha back sheet. The first encapsulating film has a zero shear viscositygreater than that of the second encapsulating film. The back sheet ofthe electronic device contains fewer bumps than the back sheet of acomparable electronic device having a first encapsulating film with azero shear viscosity less than or equal to that of the secondencapsulating film.

In another embodiment the invention is an electronic device comprising,in order, (i) a light-receiving and transmitting film, (ii) a firstencapsulating film, (iii) at least one photovoltaic cell, (iv) a secondencapsulating film, and (v) a back sheet. The first encapsulating filmis in direct contact with the light-receiving and transmitting film, thesecond encapsulating film is in direct contact with the back sheet, andthe at least one photovoltaic cell is in direct contact with the firstand second encapsulating films. The first encapsulating film has a zeroshear viscosity greater than that of the second encapsulating film.

In another embodiment the invention is a method for reducing bumps in anelectronic device comprising selecting a first encapsulant film having afirst zero shear viscosity and selecting a second encapsulant filmhaving a second zero shear viscosity such that the first zero shearviscosity is within 700 to 10,000 Pa·s of the second zero shearviscosity.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT Definitions

Unless stated to the contrary, implicit from the context, or customaryin the art, all parts and percents are based on weight. For purposes ofUnited States patent practice, the contents of any referenced patent,patent application or publication are incorporated by reference in theirentirety (or its equivalent US version is so incorporated by reference)especially with respect to the disclosure of definitions (to the extentnot inconsistent with any definitions specifically provided in thisdisclosure) and general knowledge in the art.

The numerical ranges in this disclosure are approximate, and thus mayinclude values outside of the range unless otherwise indicated.Numerical ranges include all values from and including the lower and theupper values, in increments of one unit, provided that there is aseparation of at least two units between any lower value and any highervalue. As an example, if a compositional, physical or other property,such as, for example, molecular weight, etc., is from 100 to 1,000, thenall individual values, such as 100, 101, 102, etc., and sub ranges, suchas 100 to 144, 155 to 170, 197 to 200, etc., are expressly enumerated.For ranges containing values which are less than one or containingfractional numbers greater than one (e.g., 1.1, 1.5, etc.), one unit isconsidered to be 0.0001, 0.001, 0.01 or 0.1, as appropriate. For rangescontaining single digit numbers less than ten (e.g., 1 to 5), one unitis typically considered to be 0.1. These are only examples of what isspecifically intended, and all possible combinations of numerical valuesbetween the lowest value and the highest value enumerated, are to beconsidered to be expressly stated in this disclosure. Numerical rangesare provided within this disclosure for, among other things, the meltindex and viscosity of compositions.

The terms “blend,” “polymer blend” and like terms mean a composition oftwo or more polymers. Such a blend may or may not be miscible. Such ablend may or may not be phase separated. Such a blend may or may notcontain one or more domain configurations, as determined fromtransmission electron spectroscopy, light scattering, x-ray scattering,and any other method known in the art.

The term “bump” as used herein refers a discernible displacement of theback sheet of a photovoltaic module following lamination. Bumps aretypically the result of movement transferred from the back sheet as itshrinks during lamination through the rear encapsulant layer and to theindividual solar cells. The solar cells move closer together, causingthe connector ribbons to crimp and push outward against the back sheet.As a result, bumps will remain in the back sheet after lamination. Bumpsmay be visibly discernible with the human eye, either with or withoutaid (e.g., microscopy), or detected using instrumentation (e.g.,measuring devices).

The term “comparable electronic device” refers to an electronic devicecomprising essentially the same composition as the electronic device towhich it is being compared, except that at least one of the first orsecond encapsulating films has a zero shear viscosity different thanthat of the electronic device to which it is being compared.

The terms “composition”, “formulation” and like terms mean a mixture orblend of two or more components. In the context of a mix or blend ofmaterials from which an article of manufacture is fabricated, thecomposition includes all the components of the mix, e.g., polymers,catalysts, and any other additives or agents such as cure catalysts,antioxidants, flame retardants, etc.

The terms “comprising”, “including”, “having” and like terms are notintended to exclude the presence of any additional component, step orprocedure, whether or not the same is specifically disclosed. In orderto avoid any doubt, all processes claimed through use of the term“comprising” may include one or more additional steps, pieces ofequipment or component parts, and/or materials unless stated to thecontrary. In contrast, the term, “consisting essentially of” excludesfrom the scope of any succeeding recitation any other component, step orprocedure, excepting those that are not essential to operability. Theterm “consisting of” excludes any component, step or procedure notspecifically delineated or listed. The term “or”, unless statedotherwise, refers to the listed members individually as well as in anycombination.

The term “direct contact” is a configuration whereby two components arein physical contact with each other with no intervening layer(s) and/orno intervening material(s) located between at least a portion of the twocontacting components.

The term “glass” refers to a hard, brittle, transparent solid, such asthat used for windows, bottles, or eyewear, including, but not limitedto, pure silicon dioxide (SiO₂), soda-lime glass, borosilicate glass,sugar glass, isinglass (Muscovy-glass), or aluminum oxynitride.

The term “ethylene/alpha-olefin interpolymer” refers to an interpolymerthat comprises a majority weight percent (i.e., over 50 mole percent)polymerized ethylene monomer (based on the total weight of polymerizablemonomers) and at least one alpha-olefin.

The term “ethylene-based polymer” as used herein, refer to a polymerthat comprises a majority weight percent (i.e., over 50 mole percent)polymerized ethylene monomer (based on the total weight of polymerizablemonomers), and optionally may comprise at least one polymerizedcomonomer.

The term “interpolymer” means a polymer prepared by the polymerizationof at least two different types of monomers. This generic term includescopolymers, usually employed to refer to polymers prepared from twodifferent types of monomers, and polymers prepared from more than twodifferent types of monomers, e.g., terpolymers, tetrapolymers, etc.

The term “polymer” means a polymeric compound prepared by polymerizingmonomers, whether of the same or a different type. The generic termpolymer thus embraces the term homopolymer, usually employed to refer topolymers prepared from only one type of monomer, and the terminterpolymer as defined below.

The term “thermoplastic” refers to a material which is a linear orbranched polymer which can be repeatedly softened and made flowable whenheated and returned to a hard state when cooled to room temperature.Thermoplastics can be molded or extruded into articles of anypredetermined shape when heated to the softened state.

Grafted Resin Composition

In one embodiment, a silane-grafted ethylene interpolymer is provided.Ethylene interpolymers are generally known and available. Suitableethylene interpolymers for use in the film have a relatively low densityand modulus and good optical and electrical insulating properties.

Preferably, the ethylene interpolymers are ethylene/alpha-olefininterpolymers. The alpha-olefin of the interpolymers is preferably aC₃₋₂₀ linear, branched or cyclic alpha-olefin. Some non-limitingexamples of suitable C₃₋₂₀ alpha-olefins include propene, 1-butene,4-methyl-1-pentene, 1-hexene, 1-octene, 1-decene, 1-dodecene,1-tetradecene, 1-hexadecene, 1-octadecene, 3-cyclohexyl-1-propene (allylcyclohexane), and vinyl cyclohexane.

In some embodiments, some cyclic olefins, such as norbornene and relatedolefins, may be used in place of some or all of the alpha-olefins listedabove and are considered for purposes of the describedethylene/alpha-olefin interpolymers to be included in the definition ofalpha-olefin. Similarly, styrene and related olefins (e.g., alpha-methylstyrene, etc.) are also considered alpha-olefins for purposes of thepresent grafted resin composition. However, acrylic and methacrylic acidand their respective ionomers, acrylates, methacrylates and vinylacetate are not considered alpha-olefins as used herein.

Some non-limiting examples of ethylene/alpha-olefin interpolymers usefulin the grafted resin composition include ethylene/propylene,ethylene/butene, ethylene/1-hexene, ethylene/1-octene, ethylene/styrene,ethylene/propylene/1-octene, ethylene/propylene/butene,ethylene/butene/1-octene, and ethylene/butene/styrene.Ethylene/alpha-olefin interpolymers may be random or blockinterpolymers.

Preferably, the ethylene interpolymers are ethylene/alpha-olefininterpolymers having an alpha-olefin content of at least about 1 molepercent (mole %), preferably at least about 4 mole %, more preferably atleast about 5 mole %, and even more preferably at least about 10 mole %,based on the comonomers in the interpolymer. In most embodiments, theethylene/alpha-olefin interpolymers have an alpha-olefin content of lessthan about 30 mole %, more preferably less than about 20 mole %, andeven more preferably less than about 15 mole %.

Lower density ethylene interpolymers are preferred for use in thepresent grafted resin composition. Lower density ethylene interpolymersmay be obtained by controlling the alpha-olefin content of theinterpolymer. The alpha-olefin content can be measured by ¹³C NMRspectroscopy. Generally, the greater the alpha-olefin content of theinterpolymer, the lower the density and the crystallinity. Lower densityand lower crystallinity results in more desirable physical and chemicalproperties for a film layer used in an electronic device or module.

Ethylene interpolymers suitable for use in the grafted resin compositiontypically have a density of less than or equal to about 0.905 g/cc,preferably less than about 0.90 g/cc, preferably less than 0.89 g/cc,more preferably less than about 0.885 g/cc, and even more preferablyless than about 0.88 g/cc. The density of the ethylene interpolymers isgenerally greater than about 0.85 g/cc, and more preferably greater thanabout 0.86 g/cc. Density is measured according to ASTM-D 792-03, MethodB, in isopropanol.

Preferably, ethylene interpolymers have a short chain branchdistribution index (SCBDI) or composition distribution branch index(CDBI) greater than about 30, preferably greater than about 40, morepreferably greater than about 50, even more preferably greater thanabout 80 and most preferably greater than about 90. As used herein,SCBDI and CDBI are defined as the weight percent (wt %) of the polymermolecules having comonomer content within 50% of the median total molarcomonomer content.

Preferably the ethylene interpolymers have low crystallinity, low haze,and high transmission of visible and UV light. Low modulus ethyleneinterpolymers are flexible and particularly well adapted for use in thepresent films and electronic devices because they provide stabilityunder stress and are less prone to crack upon stress or shrinkage.

Ethylene interpolymers used in the grafted resin composition have a 2%secant modulus of less than about 200 MPa, preferably less than about150 MPa, more preferably less than about 120 MPa, and even morepreferably less than about 100 MPa.

Ethylene interpolymers useful in the grafted resin composition typicallyhave a melting point of less than about 110° C., preferably less thanabout 105° C., more preferably less than about 100° C., even morepreferably less than about 95° C. and still more preferably less thanabout 90° C. Blends of ethylene interpolymers having different meltingpoints may be used as well. Ethylene interpolymers or blends of ethyleneinterpolymers with low melting points often exhibit desirableflexibility and thermoplasticity properties useful in the fabrication ofelectronic devices and modules.

The glass transition temperature (Tg) of ethylene interpolymers used inthe grafted resin composition is less than about −30° C., typically lessthan about −35° C., preferably less than about −40° C., more preferablyless than about −45° C. and even more preferably less than about −50° C.Moreover, the ethylene interpolymers also have a melt index (MI) of lessthan about 100 g/10 min, preferably less than about 75 g/10 min, morepreferably at least less than about 50 g/10 min, even more preferablyless than about 35 g/10 min, and even more preferably less than 20 g/10min as measured in accordance with ASTM D-0138 (190° C./2.16 kg). At aminimum, the MI of the interpolymers is about 1 g/10 min, preferablyabout 5 g/10 min, and even more preferably about 10 g/10 min.

In preferred embodiments, the ethylene interpolymer is a thermoplasticethylene interpolymer.

Ethylene interpolymers useful in the present grafted resin compositionare typically made with a constrained geometry catalyst, a metallocenecatalyst, or a post-metallocene catalyst. Such single-site catalysttechnology is generally known. Some non-limiting suitable catalysts usedfor preparing ethylene interpolymers of the present invention includebis-(biphenylphenol) ligands coordinated through oxygen atoms to atransition metal (Ti, Zr and Hf) such as, for example, using as thecomplex[2,2′″-[1,3-propanediylbis(oxy-kO)]bis[3″,5,5″-tris(1,1-dimethylethyl)-5′-methyl[1,1′:3′,1″-terphenyl]-2′-olato-kO]]dimethyl.

Specific examples of ethylene interpolymers used in the grafted resincomposition include very low density polyethylene (VLDPE), homogeneouslybranched, linear ethylene/alpha-olefin interpolymers, and homogeneouslybranched, substantially linear ethylene/alpha-olefin polymers (e.g.,plastomers and elastomers) prepared using the preferredcatalyst/cocatalyst systems described above. Most preferably, theethylene interpolymers are homogeneously branched linear andsubstantially linear ethylene interpolymers.

Blends of any of the ethylene interpolymers described above may also beused, and the ethylene interpolymers may be blended or diluted with oneor more other polymers to the extent that the polymers are (i) misciblewith one another, (ii) the other polymers have little, if any, impact onthe desirable properties of the ethylene interpolymer (i.e., optics andlow modulus), and (iii) the ethylene interpolymers constitute at least70 wt %, preferably at least about 75 wt % and more preferably at leastabout 80 wt % of the blend.

When a blend of two or more ethylene interpolymers is used, the overallMI is preferably less than about 100 g/10 min, preferably less thanabout 75 g/10 min, more preferably at least about 50 g/10 min, even morepreferably less than about 35 g/10 min, and even more preferably lessthan 20 g/10 min as measured in accordance with ASTM D-0138 (190°C./2.16 kg). At a minimum, the MI of the interpolymers is about 1 g/10min, preferably about 5 g/10 min, and even more preferably about 10 g/10min.

Preferably, the ethylene interpolymers or ethylene interpolymers usedwill have a zero shear viscosity from about 200 to about 20,000 Pa·s.

To improve the adhesion of the ethylene interpolymers when incorporatedinto an electronic device or module, silane functionality is introducedto the interpolymers. The interpolymers also preferably benefit frombeing crosslinked at the time of contact or after, usually shortlyafter, the device or module has been constructed. Crosslinking enhancesthe thermal creep resistance of the interpolymer and durability of themodule by increasing heat, impact and solvent resistance.

Silane functionality is introduced to the ethylene interpolymers bygrafting or otherwise bonding an alkoxysilane to the ethyleneinterpolymer. Preferably, an alkoxysilane group having the followinggeneral formula (I) is grafted to the ethylene interpolymer:—CH₂—CHR¹—(R²)_(m)—Si(R³)_(3-n)(OR⁴)_(n)  Formula (I)wherein R¹ is H or CH; R² and R³ are, independently, an alkyl, aryl orhydrocarbyl containing from 1 to 20 carbon atoms and may also includeother functional groups, such as esters, amides, and ethers; m is 0 or1; R⁴ is an alkyl or carboxyalkyl containing from 1 to 6 carbon atoms(preferably methyl or ethyl); and n is 1, 2 or preferably 3.

Preferred alkoxysilane compounds suitable for grafting includeunsaturated alkoxysilanes where (1) the ethylenically unsaturatedhydrocarbyl groups in formula (I) can be a vinyl, allyl, isopropenyl,butenyl, cyclohexenyl, or (meth)acryloxyalkyl (refers to acryloxyalkyland/or methacryloxyalkyl) group, (2) the hydrolysable group (OR⁴) can bea hydrocarbyloxy, hydrocarbonyloxy, or hydrocarbylamino group such asmethoxy, ethoxy, propoxy, butoxy, formyloxy, acetoxy, propionyloxy andalkyl- or arylamino groups, and (3) the saturated hydrocarbyl group (R³)can be methyl or ethyl. Some non-limiting examples of preferredalkoxysilanes include vinyltrimethoxysilane (VTMOS),vinyltriethoxysilane (VTEOS), allyltrimethoxysilane, allyltriethoxysilane, 3-acryloylpropyltrimethoxysilane,3-acryloylpropyltriethoxysilane, 3-methacryloylpropyltrimethoxysilane,and 3-methacryloylpropyltriethoxysilane and mixtures of these silanes.

Typically there is at least 0.1 wt % alkoxysilane in the graftedinterpolymer, preferably at least about 0.5 wt %, more preferably atleast about 0.75 wt %, even more preferably at least about 1 wt % andmore preferably at least about 1.2 wt %. The grafted interpolymerusually contains less than 10 wt %, preferably less than or equal toabout 5 wt %, and more preferably less than or equal to 2 wt %alkoxysilane.

Grafted techniques and process are well known in the art and includeusing free radical graft initiators such as, for example, peroxides andazo compounds, or ionizing radiation. Organic free radical graftinitiators are preferred, such as dicumyl peroxide, di-tert-butylperoxide, t-butyl perbenzoate, benzoyl peroxide, cumene hydroperoxide,t-butyl peroctoate, methyl ethyl ketone peroxide,2,5-dimethly-2,5-di(t-butyl peroxy)hexane, lauryl peroxide, andtert0butyl peracetate. A suitable azo compound is azobisisobutylnitrile.

While any of the grafting processes known in the art may be used, onenon-limiting example of a grafting process includes blending thealkoxysilane and ethylene interpolymer with a graft initiator in thefirst stage of a reactor extruder, such as a Buss kneader. Graftingconditions may vary, but the melt temperatures are typically between160° C. and 260° C., and preferably between 190° C. and 230° C.,depending on the residence time and half-life of the initiator.

If crosslinking is desired, the grafted resin composition willpreferably have a gel content of at least 30%, more preferably at least40%, even more preferably at least 50% and most preferably at least 60%,as measured in accordance with ASTM D-2765.

Crosslinking methods and processes are well known in the art, and anysuitable method may be used to crosslinking the silane-grafted ethyleneinterpolymers used in the grafted resin composition. A non-limitingcrosslinking method includes moisture (water) curing using ahydrolysis/condensation catalyst. Such catalysts include, for example,Lewis acids such as dibutyltin dilaurate, dioctyltin dilaurate, stannousoctonoate, and hydrogen sulfonates such as sulfonic acid. UV light orsunlight may also be used to promote crosslinking, preferably using oneor more photoinitiators. Non-limiting examples of photoinitiatorsinclude organic carbonyl compounds such as benzophenone, benzanthrone,benzoin and alkyl ethers thereof, 2,2-diethoxyacetophenone,2,2-dimethoxy, 2 phenylacetophenone, p-phenoxy dichloroacetophenone,2-hydroxycyclohexylphenone, 2-hydroxyi sopropylphenone, and1-phenylpropanedione-2-(ethoxy carboxyl)oxime. Initiators may be used inaccepted known quantities, typically at least about 0.05 wt % based onthe weight of the interpolymer, more typically at least 0.1 wt % andeven more typically about 0.5 wt %.

Free radical crosslinking cocatalysts may also be used, includingmultifunctional vinyl monomers and polymers, triallyl cyanurate andtrimethylolpropane trimethacrylate, divinyl benzene, acrylates andmethactrylates of polyols, allyl alcohol derivatives, and low molecularweight polybutadiene. Sulfur crosslinking coagents include benzothaizyldisulfide, 2-mercaptobenzothiazole, copper dimethyldithiocarbamate,dipentamethylene thiuram tetrasulfide, tetrabutylthiuram disulfide,tetramethylthiuram disulfide and tetramethylthiuram monosulfide. Thesecoagents may be used in accepted and known quantities, typically atleast about 0.05 wt % based on the weight of the interpolymer, moretypically at least about 0.1 wt %, and most preferably at least about0.5 wt %. Typically, the maximum amount of cocatalyst used is less than10 wt %, preferably less than about 5 wt %, and most preferably lessthan about 3 wt %.

One difficulty in using thermally activated free radical initiators topromote crosslinking is that they may initiate premature crosslinking.Premature crosslinking results from thermal decomposition of the freeradical initiator, which results in scorch. Methods of minimizing scorchare known in the art and include introducing scorch inhibitors into thegrafted resin composition. Non-limiting examples of scorch inhibitorsinclude organic hydroperoxides, N-nitroso diphenylamine,N,N′-dinitroso-para-phenylamine, isoamyl nitrite, tert-decyl nitrite,monomeric vinyl compounds, aromatic amines, phenolic compounds,mercaptothiazole compounds, bis(N,N-disbustituted-thiocarbamoyl)sulfides, hydroquinones, dialkyldithiocarbamate compounds, mixtures ofmetal salts of disubstituted dithiocarbamic acid,4-hydroxy-2,2,6,6-tetramethylpiperidin-1-oxyl.

Scorch inhibitors may be used in known amounts, typically at a minimumof at least about 0.01 wt %, preferably at least about 0.05 wt %, morepreferably at least about 0.1 wt % and most preferably at least about0.15 wt % based on the weight of an interpolymer having 1.7 wt %peroxide. Typically the maximum amount of scorch inhibitor used does notexceed 2 wt %, preferably does not exceed about 1.5 wt %, and morepreferably does not exceed about 1 wt % of an interpolymer having 1.7 wt% peroxide.

Other additives may be included with the silane-grafted ethyleneinterpolymer. Other additives include UV absorbers, UV stabilizers,processing stabilizers, antioxidants, anti-blocks, anti-slips, pigmentsand fillers known in the art. Additives are used in the manner andamount as commonly known in the art.

Encapsulation Film

In one embodiment, a film or a film layer comprising a blend of (A) asilane-containing ethylene interpolymer and (B) at least oneethylene/alpha-olefin interpolymer is provided. As used herein, a filmmay be a monolayer or multilayer film. The terms “layer” and “filmlayer” refer to an individual layer or layers of an overall thickerarticle (the film). The term “film” as used herein, including when usedin the phrase “film layer” and when used to refer to an individual layeror layers, and unless expressly having a specified thickness, includesany relatively thin, flat extruded or cast thermoplastic article havinga generally consistent and uniform thickness as needed for use inelectronic devices.

Preferably, the film described herein has a thickness of up to about 25mils (0.64 mm) and more preferably less than about 20 mils (0.51 mm).Film layers may be very thin, and may be as thin as 10 nm when used in amicrolayer film. Generally, film layers of the present film have athickness of at least about 1 mil (25 μm), preferably at least about 2mils (51 μm), and more preferably at least about 3 mils (75 μm).

The silane-containing ethylene interpolymer is as set forth in any ofthe embodiments above. The at least one ethylene/alpha-olefininterpolymer may be any of the ethylene/alpha-olefin interpolymersdescribed and suitable for use in the silane-containing ethyleneinterpolymer but without the silane functionality. In some embodiments,(A) and (B) may be a blend of two or more silane-containing ethyleneinterpolymers or ethylene/alpha-olefin interpolymers, respectively.

The composition comprising (A) a silane-containing ethylene interpolymerand (B) at least one ethylene/alpha-olefin interpolymer can contain from1 wt % to 100 wt % (A). In preferred embodiments, the compositioncontains from 5 wt % to 100 wt % (A) and from 0 wt % to 80 wt % (B). Instill further embodiments, the composition comprising (A) asilane-containing ethylene interpolymer and (B) at least oneethylene/alpha-olefin interpolymer may also contain additives, such asUV stabilizers, antioxidants and other compounds known in the art. Theseadditives may be provided in known quantities, and, in some embodiments,may be added in the form of a masterbatch, that is pre-blended in anamount of polymer composition.

The composition comprising (A) a silane-containing ethylene interpolymerand (B) at least one ethylene/alpha-olefin interpolymer may befabricated into a monolayer film or at least one film layer, preferablyas a surface layer, of a multilayer film. The general methods for thepreparation of films are generally known in the art and the equipment isgenerally commercially available. Such films may be prepared by, forexample, cast, blown, calendared, or extrusion coating processes; andcomposite or laminate structures made with any of the foregoingarticles.

Preferably, the composition comprising (A) a silane-containing ethyleneinterpolymer and (B) at least one ethylene/alpha-olefin interpolymer maybe formed into an encapsulant layer for use as a layer in a laminatedstructure, such as a PV module.

Electronic Devices

Films comprising the grafted resin composition such as those describedin any above embodiment may be included in a laminated structure. Thegrafted resin composition may be provided as a monolayer film or as amultilayer film with at least one additional layer, such as glass or asurface of an electronic device.

Films of many types of materials can be employed in laminate structureswith the grafted resin composition. In addition to glass, other films,including cover films, protective films, and top and/or back films maybe included in a laminated structure. Non-limiting examples of materialsfor such films include polycarbonate, acrylic polymers, polyacrylate,cyclic polyolefins such as ethylene norbornene, metallocene-catalyzedpolystyrene, polyethylene terephthalate, polyethylene naphthalate,fluoropolymers such as ethylene-tetrafluoroethylene (ETFE), polyvinylfluoride (PVF), fluoroethylene-propylene (FEP),ethylene-chlorotrifluoroethylene (ECTFE), and polyvinylidene fluoride(PVDF).

Various methods are known in the art for making laminated structure.Generally, a laminated structure of any of the above embodiments is madeby (1) positioning the film (e.g., a monolayer of the grafted resincomposition or a multilayered film including the grafted resincomposition) and at least one other film (e.g., glass) such that afacial surface of the film containing the silane-containing interpolymeris indirect contact with a facial surface of the other film, (2)laminating and adhering the first and second films at a laminationtemperature, and, optionally, (3) crosslinking the silane-containinginterpolymer. In some embodiments, crosslinking and laminating andadhering the layers may occur in the reverse order or simultaneously.

The films of a laminated structure may be applied to each other in anysuitable manner known in the art, including, but not limited to, vacuumlamination, extrusion, calendaring, solution casting and injectionmolding.

Preferably, the films of the embodiments described above can be used tocreate a laminated structure which is an electronic device or module.More preferably, the films of the embodiments described above can beused as skin films or encapsulant films to construct electronic devicemodules (e.g., photovoltaic or solar cells) in the same manner and usingthe same amounts as the skin or encapsulant materials known in the art.

In a preferred aspect of the invention, laminated PV structurescomprise, in sequence, starting from the “top film” which the lightinitially contacts: (i) a light-receiving and transmitting top sheet orcover sheet film, usually comprising glass, (ii) a front encapsulatingfilm, (iii) photovoltaic cells, (iv) a rear encapsulating film, and (v)a back sheet film, usually comprising glass or other polymer filmstructure back layer substrate. The number of photovoltaic cells in agiven electronic device will vary depending on the nature and use of thedevice.

A back sheet used in laminated PV structures is a multilayered structurewhich protects the back surface of a PV structure. Generally, backsheets may a core polyethylene terephthalate (PET) layer or othermaterial layer which is shrinks during lamination.

Both the front encapsulating film and the rear encapsulating film may befilms as described herein. Preferably, a single encapsulating film, mostpreferably the rear encapsulating film, is a film as described in any ofthe above embodiments comprising the grafted resin composition.

The films (i)-(v) of a laminated PV structure described above are bondedthrough lamination. Through lamination, the top sheet is brought intodirect contact with the front encapsulating film, and the back sheet isbrought into direct contact with the rear encapsulating film. Thephotovoltaic cells are secured between, and in direct contact with, thefront and rear encapsulating films. As a result, portions of the frontand rear encapsulating films are in direct contact with each other.

Lamination processes used to create electronic devices, and specificallythe preferred laminated PV structure, require a step with heating andcompressing at conditions sufficient to create the needed adhesionbetween the films. In general, lamination temperatures will depend onthe specific polymer content of the layers. At the lower end, laminationtemperatures need to be at least about 120° C., preferably at leastabout 130° C. and, at the upper end, less than or equal to about 180°C., preferably less than or equal to about 170° C.

The elevated temperatures required for lamination cause some polymermaterials, such as the encapsulating films and back sheet of the PVstructure, to shrink, resulting in movement of the films relative toeach other during lamination. Usually, the back sheet is the film havinga propensity to shrink, resulting in movement of the rear encapsulatingfilm and subsequent films. That movement causes the PV cells to movecloser to each other during lamination and the ribbons connecting thecells to buckle or fold back on themselves. The ribbons push back outagainst the rear encapsulating film and back sheet, causing bumps in theback sheet.

It was surprisingly discovered that using encapsulating films havingdifferent zero shear viscosity values, and specifically having a front(in contact with the light-receiving and transmitting film)encapsulating film with a zero shear viscosity greater than that of arear (in contact with the back sheet) encapsulating film, prevents thetransfer of movement caused by the shrinking back sheet throughout therest of an electronic device. As a result, an electronic device havingencapsulating films with this difference in zero shear viscosities showfewer bumps in the back sheet compared to the back sheet of a comparableelectronic device having encapsulating films with equal zero shearviscosities or a front encapsulating film with a zero shear viscosityless than that of the rear encapsulating layer.

Preferably, the zero shear viscosity of the front encapsulating film,which is in direct contact with the light-receiving/transmitting film,is greater than that of the second encapsulating film, which is indirect contact with the back sheet. More preferably, the zero shearviscosity of the front encapsulating film is 700-10,000 Pa·s, morepreferably 1,000-8,000 Pa·s, and most preferably 2,000-6,000 Pa·s.

In preferred embodiments, the rear encapsulating film is a film asdescribed in any above embodiments, having a zero shear viscosity of200-2,000 Pa·s, more preferably 400-900 Pa·s, even more preferably500-900 Pa·s and most preferably 600-800 Pa·s. In other embodiments, therear encapsulating film may be any material suitable for use as anencapsulant and having a viscosity less than the front encapsulatingfilm.

The zero shear viscosity of the front and rear encapsulating filmsshould be at least 100 Pa·s apart. As the difference between the zeroshear viscosity of the front encapsulating film and the rearencapsulating film become less than 100 Pa·s, the beneficialbump-reducing effect is reduced. While the difference in zero shearviscosity between the front and rear encapsulating films may be up to10,000 Pa·s, there is little additional benefit beyond a difference of5,000 Pa·s.

Not to be bound by any particular theory, it is thought that as the PETcore layer or other high-shrinkage layer of the back sheet shrinks, therear encapsulating film does not resist the movement of the back sheet.It remains bonded to the solar cells as well, but, because there is lessintegrity to the film (i.e., lower shear viscosity), the film does notcause the cells to move. In other words, when the back sheet shrinks,the rear encapsulating film is better able to disperse the shear stresscaused by the back sheet before it reaches the cells or the frontencapsulating film. In effect, it is hypothesized that the rearencapsulating film of the present invention acts as an internal stressreducer. This is in contrast to a standard, crosslinked EVA rearencapsulating film which would lock in the stress caused by theshrinking back sheet.

In another embodiment, a method of reducing bumps in an electronicdevice is provided. The method includes selecting a first encapsulantfilm have a first zero shear viscosity and selecting a secondencapsulant film having a second zero shear viscosity such that thefirst zero shear viscosity is within 700 to 10,000 Pa·s of the secondzero shear viscosity. These two encapsulant films are then used informing a laminated structure by (1) bringing a light-receiving andtransmitting top sheet in direct contact with the first encapsulantfilm, (2) bringing a back sheet in direct contact with the secondencapsulant film, (3) securing at least one photovoltaic cell betweenand in direct contact with the first and second encapsulant films suchthat portions of the first and second encapsulant films are in directcontact with each other, and (4) laminating and adhering thelight-receiving and transmitting top sheet, first encapsulant film,second encapsulant film and back sheet at a lamination temperature. Thesilane-containing interpolymers of the encapsulant films may also becrosslinked.

The following examples are illustrative of certain embodiments of thepresent invention. All parts and percentages are based on weight exceptas otherwise indicated.

Specific Embodiments Materials

Luperox 101 peroxide: 2,5-bis(tert-butylperoxy)-2,5-dimethylhexane,provided by Arkema Inc.

E/O 1: “E/O 1” is an ethylene/octene interpolymer having a density of0.870 g/cc and an MI of 5 g/10 min.

E/O 2: “E/O 2” is an ethylene/octene interpolymer having a density of0.902 g/cc and an MI of 30 g/10 min.

E/O 3: “E/O 3” is an ethyl ene/octene interpolymer having a density of0.902 g/cc and an MI of 3 g/10 min.

E/O 4: “E/O 4” is an ethylene/octene interpolymer having a density of0.885 g/cc and an MI of 18 g/10 min.

Masterbatch: “Masterbatch” is a masterbatch with additives made with anethylene/octene copolymer having a density of 0.870 g/cc and an MI of 5g/10 min carrier resin.

Protekt HD (Madico): Protekt HD is a backsheet comprising the structurefluoropolymer/polyethylene terephthalate/ethylene-vinyl acetate(fluoropolymer/PET/EVA).

Dunmore-1360 PPE+: Dunmore-1360 PPE+ is a backsheet comprising thestructure PET/PET/EVA.

Saiwu Cybrid KPE: Saiwu Cybrid KPE is a backsheet comprising thestructure fluoropolymer/PET/EVA.

Dunmore 1100 PPE+SW: Dunmore 1100 PPE+SW is a backsheet comprising thestructure PET/PET/EVA.

Dunmore 1360 PPE+ Ultra Clear: Dunmore 1360 PPE+ Ultra Clear is a backsheet comprising the structure PET/PET/EVA.

Krempel Akasol PTL 2-38/250 TPE: Krempel Akasol PTL 2-38/250 TPE is abacksheet comprising the structure Tedlar/PET/EVA.

Testing Methodology

Glass Adhesion: The glass adhesion of the films described herein wasdetermined by laminating a structure of glass with a 1^(st) encapsulantfilm, a 2^(nd) encapsulant film and TPE back sheet at 150° C. on avacuum laminator for 3 minutes of vacuum followed by 7 minutes ofpressure at one atmosphere. Two pieces of encapsulant were used tosimulate the structure of a solar module. The laminated glass structurewas then tested by 180° peel in an Instron at 2 inches per minute. Theaverage value of the region between 1 inch and 2 inches was reported.

Optical Transmission: A monolayer of film as described herein wassubjected to a lamination cycle on a vacuum laminator at 150° C. for 3minutes of vacuum followed by 7 minutes of pressure at one atmosphere.The optical transmission of the film was measured using a Perkin ElmerLambda 35 spectrophotometer in accordance with ASTM D1003, method B.

Haze: A monolayer of film was laminated between two layers of glass tomimic the single layer of film present between the glass and the cellsof a solar module (the most dominant visual aesthetic component of asolar module). The yellowness index was measured before and after dampheat testing at 85° C. and 85% relative humidity using ASTM E313.

Tensile Strain: Tensile stress is determined according to ASTM D882-12.

Tensile Stress: Tensile stress is determined according to ASTM D882-12.

Toughness: Toughness is determined according to ASTM D882-12 and is thearea under the stress-strain curve.

Modulus: The modulus is determined by calculating the slope of theinitial linear region of the tensile stress curve according to ASTMD882-12.

Encapsulating Film Preparation

The saline-grafted resin was compounded using a twin screw reactiveextrusion process. The grafted resin was cut into pellets and stored ina foil bag. Separately, a master batch with thermal and UV stabilizerswas compounded using an FCM extruder. Film samples with 457 μm thicknesswere prepared on a 3-layer cast co-extrusion line. The three extruderswere all 25 mm in diameter with Maddock mixing sections and the screwend. The casting roll was always contacting the B extruder and the Cextruder was always the core. Die width was 300 mm.

Table 1 shows the film formulations used in examples 1-2 and comparativeexample 1. The formulations were purged in for 15 minutes representing7.5 residence time in the extruders at 80 RPM.

TABLE 1 Film Formulations in Percent Based on Total Weight (wt %)Comparative Example 1 Example 2 Example 1 Grafted Resin CompositionVinyl trimethoxy silane 1.905 1.905 1.905 Luperox 101 peroxide 0.0950.095 0.095 E/O 1 44.1 16.6 83.3 E/O 2 39.2 21.1 E/O 3 14.7 E/O 4 14.760.3 Final Film Composition Grafted resin composition (above) 65.0 65.065.0 E/O 1 25.0 E/O 4 25.0 25.0 Masterbatch 10.0 10.0 10.0

PV Module Preparation

156 mm by 156 mm PV cells, such as those available from Ever BrightSolar, were used to create the PV modules for examples 1-2 andcomparative example 1. 9-cell mono-crystalline strings were created,with the PV cells positioned 3 mm apart and connected by 76.2 mm lengthsof buss ribbon, such as tin coated copper buss ribbon. In furtherembodiments, multi-crystalline cells may be used as well. Frontencapsulant films, rear encapsulant films and back sheets were cut tosize in the machine direction of the film. For the 9-cell strings used,the encapsulating films and back sheets were cut to 215.9 mm by 1524 mm.3 mm glass, washed, squeegeed and toweled dry, was used for the topsheets.

The PV modules were assembled for lamination on a Teflon sheet in thefollowing order: glass, front encapsulating film (embossed side toglass, approximately 25.4 mm from the bottom edge of the glass), PV cellstring (face down and centered on front encapsulating layer), rearencapsulating film (embossed side to string), and back sheet. Theassembled modules were covered with a Teflon sheet.

The assembly was pulled into a P-Energy L200A laminator. The laminationcondition was 150° C. with a vacuum pump time of 3 minutes and a holdtime of 7 minutes at 1000 mBar. The laminated structures were pulledfrom the laminator and cooled at room temperature for approximately 1minute prior to removing the top Teflon sheet.

Results

The electrical, optical and adhesion properties of the formulations inTable 1 are provided in Table 2 below. As shown, the encapsulating filmsof Examples 1 and 2 have a significantly lower zero shear viscosity thanComparative Example 1 while retaining approximately the sametransmission, haze and clarity. Examples 1 and 2 also exhibit excellentglass adhesion comparable to Comparative Example 1.

TABLE 2 Electrical, Optical and Adhesion Properties Volume Adhesion ZeroShear Resistivity Transmission Haze Clarity to Glass Viscosity (ohm-cm)(%) (%) (%) (lb-f/in) (Pa*s) Example 1   2 x 10¹⁵ 88.8 23.0 99.2 109.4700 Example 2 1.6 x 10¹⁵ 87.7 31.0 99.1 100.8 860 Comparative 1 4.9 x10¹⁵ 87.3 19.7 99.6 103.3 4065

The tensile strength of the formulations in Table 1 is provided in Table3, below. Example 1 has a lower modulus than Comparative Example 1,indicating better elasticity. Example 1 also has a lower strain atbreak.

TABLE 3 Tensile Strength for 457 μm Thick Film (20 inches per minute, 2inch gap) Tensile Tensile Tensile Stress at Thickness Strain at Stressat Toughness Yield Modulus Films Direction (in) Break (%) Break (psi)(psi) (MPa) (MPa) Example 1 MD 0.019 896 1500 6560 2.95 1.62 TD 0.019872 1480 6530 2.90 1.67 Comparative 1 MD 0.019 946 1500 6540 2.42 1.93TD 0.019 918 1390 6070 2.44 1.80

Various back sheet and encapsulating film combinations were tested forthe formation of bumps after lamination. Table 4 shows the back sheetand encapsulating film combinations tested. The number of bumps on theback sheet was determined by visual inspection.

Applicants surprisingly and unexpectedly discovered that using a rearencapsulating film having a shear viscosity less than the shearviscosity of the front encapsulating film greatly reduced the presenceof bumps in the PV module back sheet. Applicants surprisingly discoveredthat a difference of at least 140 Pa·s or greater between the front andrear encapsulant films dramatically reduces bumps. Smaller differencesalso surprisingly show a reduction in bumps.

Not to be bound by any particular theory, Applicants believe that as thecore layer (usually PET) of the back sheet shrinks, the rearencapsulating film does not resist the movement of the back sheet. Itremains bonded to the solar cells as well, but, because there is lessintegrity to the film (i.e., lower shear viscosity), the film does notcause the cells to move. In other words, when the back sheet shrinks,the rear encapsulating film is better able to disperse the shear stresscaused by the back sheet before it reaches the cells or the frontencapsulating film. In effect, it is hypothesized that the rearencapsulating film of the present invention acts as an internal stressreducer. This is in contrast to a standard, crosslinked EVA rearencapsulating film which would lock in the stress caused by theshrinking back sheet.

As seen in Table 4, the number of bumps visible in the back sheet issignificantly reduced, and in some cases eliminated, when the zero shearviscosity of the rear encapsulant film is less than that of frontencapsulant film. The combination of Comparative Example 1 as the frontencapsulant film and Example 1 as the rear encapsulant film showedimproved results over the combination of Comparative Example 1 as thefront encapsulant film and Example 2 as the rear encapsulant film.Applicants believe this result is attributable to the increaseddifference in viscosity between Comparative Example 1 and Example 1 (azero shear viscosity difference of 3,365) as compared to that ofComparative Example 1 and Example 2 (a zero shear viscosity differenceof 3,205).

TABLE 4 Encapsulant Film and Back Sheet Combinations and Bump FormationFront Encapsulant Film C1 C1 C1 Rear Encapsulant Film C1 E1 E2 BackSheet Number Number Number of Bumps of Bumps of Bumps Coveme TS APYE 6 0Protekt HD (Madico) 4 0 0 Dunmore-1360 PPE+ 1 0 Saiwu Cybrid KPE 5 0Dunmore 1100 PPE+ SW 4 0 2 Dunmore 1360 PPE + Ultra 0 0 0 Clear KrempelAkasol PTL 2- 4 0 1 38/250 TPE Krempel Akalight 2 0 4 As used in theabove table, C1 is Comparative Example 1, E1 is Example 1 and E2 isExample 2.

Applicants also surprisingly discovered that the stress shrink of agiven back sheet may also contribute a given encapsulant filmcombination's effectiveness in reducing bumps. As illustrated in Table4, back sheets having higher stress shrink values tend to show morebumps, in general. The best bump reduction was achieved when thedifference in zero shear viscosity between the rear encapsulant film andthe front encapsulant film was greater.

It is specifically intended that the present invention not be limited tothe embodiments and illustrations contained herein, but include modifiedforms of those embodiments including portions of the embodiments andcombinations of elements of different embodiments as come within thescope of the following claims.

We claim:
 1. An electronic device comprising: a top sheet; a frontencapsulant film in direct contact with the top sheet, the frontencapsulant film composed of a first ethylene/alpha-olefin copolymercomposition having a first zero shear viscosity (ZSV) value; aphotovoltaic module having a top surface in direct contact with thefront encapsulant film, the photovoltaic cell having ribbons extendingtherefrom; a rear encapsulant film in direct contact with a bottomsurface of the photovoltaic module, the rear encapsulant film composedof a second ethylene/alpha-olefin copolymer composition having a secondZSV value, the second ZSV value is from 700 Pa·s to 860 Pa·s and thefirst ZSV value is 4065 Pa·s; a backsheet in direct contact with therear encapsulant film, the backsheet having an unshrunken pre-laminationstate and a shrunken post-laminated state, the backsheet imparting ashear stress upon the rear encapsulant film when the backsheet issubject to lamination conditions and moves from the pre-lamination stateto the post-lamination state; and the second ethylene/alpha olefincomposition disperses the shear stress such that the shear stress doesnot reach the photovoltaic module.
 2. The electronic device of claim 1wherein the electronic device exhibits no bumps.
 3. The electronicdevice of claim 2 wherein the ribbons are not buckled.
 4. The electronicdevice of claim 3 wherein the backsheet comprises a layer composed ofpolyethylene terephthalate.
 5. The electronic device of claim 4 whereina portion of the front encapsulant film is in direct contact with aportion of the rear encapsulant film.
 6. The electronic device of claim5 wherein the first ethylene/alpha-olefin copolymer composition is ablend of ethylene/alpha-olefin copolymers; the secondethylene/alpha-olefin copolymer composition is a blend ofethylene/alpha-olefin copolymers; and first ethylene/alpha-olefincopolymer composition includes at least one ethylene/alpha-olefincopolymer that is different than the ethylene/alpha-olefin copolymerspresent in the second ethylene/alpha-olefin copolymer composition. 7.The electronic device of claim 1, wherein the secondethylene/alpha-olefin copolymer composition has a ZSV value of 860 Pa·s.8. The electronic device of claim 7, wherein the first ZSV value is from3,205 to 3,365 Pa·s greater than the second ZSV value.
 9. The electronicdevice of claim 1, wherein the second ethylene/alpha-olefin copolymercomposition has a ZSV value of 700 Pa·s.
 10. A process comprising:providing an assembly in the following order (i) a top sheet, (ii) afront encapsulant film, (iii) a photovoltaic module, the photovoltaicmodule having ribbons extending therefrom, (iv) a rear encapsulant film,and (v) a backsheet; providing a first ethylene/alpha-olefin copolymercomposition having a first zero shear viscosity (ZSV) value for thefront encapsulant film and providing a second ethylene/alpha-olefincopolymer composition having a second ZSV value for the rear encapsulantfilm such that the second ZSV value is from 700 Pa·s to 860 Pa·s and thefirst ZSV value is 4065 Pa·s; subjecting the assembly to laminationconditions; shrinking, under the lamination conditions, the backsheet;imparting, with the shrinking, a shear stress onto the rear encapsulantfilm; dispersing the shear stress with second ethylene/alpha-olefincopolymer such that the shear stress does not reach the photovoltaicmodule; and forming an electronic device.
 11. The process of claim 10comprising preventing, with the dispersing, the ribbons from buckling;and forming an electronic device exhibiting no bumps.
 12. The process ofclaim 11 comprising providing a backsheet comprising a layer composed ofpolyethylene terephthalate.
 13. The process of claim 12 comprisingsubjecting the assembly to lamination conditions including a laminationtemperature from 120° C. to 170° C.
 14. The process of claim 10, whereinthe second ZSV value is 700 Pa·s.
 15. The process of claim 14, whereinthe first ZSV value is from 3,205 to 3,365 Pa·s greater than the secondZSV value.